Sr. Process Engineer

Job Title

Sr. Process Engineer

Lincolnshire, IL

Ingersoll Rand has dedicated itself to Making Life Better for its employees, customers, shareholders, and planets. We produce innovative and mission‑critical flow creation and life science technologies—from compressors to precision handling of liquids, gases, and powers—to increase industrial productivity, efficiency, and sustainability. Our products are used in various end markets including life sciences, food and beverage, clean energy, industrial manufacturing, infrastructure, and more.

The Process Engineer is responsible for the development, optimization, and sustaining robust molding processes for liquid silicone rubber (LSR) and high consistency rubber (HCR) utilizing injection, transfer, and compression molding processes. The Engineer drives process capability, optimizes cycle times, reduces scrap, troubleshoots production issues, and ensures stable manufacturing performance across all molding work centers. Collaboration with Tooling, Production, Quality, NPI, and Maintenance teams is essential for successful product launches, consistent quality, and efficient manufacturing processes.

• Develop, validate, and optimize molding processes for LSR injection molding, HCR injection, compression, and transfer molding, multi‑cavity family molds, and multi‑shot configurations.
• Apply scientific molding techniques to establish injection/fill profiles, pack/hold strategies, cure and thermal control profiles, venting and flash prevention parameters.
• Perform process determination and DOE studies to improve capability (Cp/Cpk) and reduce variation.
• Establish and maintain standardized process parameter sheets, recipes, and work instructions.

• Provide daily technical support for molding issues such as flash, short shots, cure variations, knit lines, voids, sticking, ejection problems, and inconsistent shrink, durometer, and dimensional stability.
• Lead root cause analysis (5 why, 8D, fishbone) and implement corrective and preventive actions.
• Train operators and technicians in molding best practices and process discipline.

• Partner with Tooling Engineers on gate/vent design, cold runner or valve‑gate LSR systems, mold thermal management, vent maintenance, mold qualification, and production readiness.
• Support maintenance to ensure equipment operates within validated performance parameters and provide feedback to improve mold robustness and reduce tool wear.

• Drive improvements in cycle time, scrap and rework reduction, OEE, material usage, and yield optimization.
• Participate in LEAN, Kaizen, 5S, and efficiency projects; use SPC, data analytics, and process monitoring to identify and address instability.

• Work with NPI Engineering on feasibility reviews, new mold trials, qualification, launch readiness, and transfer to production.
• Support Quoting/Estimating with cycle time projections, material behavior expectations, and tooling strategy input.
• Communicate clearly with Production and Quality teams on process changes, risks, and improvement projects.

• Cooperate and conduct professionally with coworkers, staff, and managers.
• Adhere to Flexan corporate values:
  Quality, Accountability, Respect, Innovation, Integrity, Open & Honest Communications, Teamwork, and Customer Focus.

• Bachelor's degree in Mechanical, Manufacturing, Materials, Plastics, or Polymer Engineering.
• 5+ years of direct experience in silicone or rubber molding with strong understanding of LSR injection, HCR molding, compression and transfer molding, cure cycles, post‑cure, and material behavior.
• Experience with tool design elements (cavitation, gating, venting, steel types).
• Proficiency in DOE, SPC, and statistical tools for process improvement.
• Strong ability to interpret engineering drawings, GD&T, CAD models, and customer specifications.
• Demonstrated success in troubleshooting complex molding issues.

• Experience with Solid Works or other 3D modeling software.
• Experience with mold flow…